The Contact Process (CIE IGCSE Chemistry)

• Sulfuric acid is synthesised by the Contact process
• Concentrated sulfuric acid is used in car batteries, making fertilisers, soaps and detergents
• The first stage is the production of sulfur dioxide, either by burning sulfur to oxidise the sulfur (equation shown below), or roasting sulfide ores 

S + O₂ → SO₂

• The main stage in the Contact process is the oxidation of sulfur dioxide to sulfur trioxide using a vanadium(V) oxide, V₂O₅, catalyst:

2SO₂ + O₂    2SO₃

• The oxygen used in this stage is obtained from air
• The conditions for this main stage of production are:
  • A temperature of 450 ºC
  • A pressure of 2 atm (200 kPa)
• Once sulfur trioxide is formed, it undergoes more processes to produce sulfuric acid

• Similar to the Haber process, the pressure and temperature used need to be considered
• The equation for the main stage of the Contact process is:

2SO₂ + O₂    2SO₃

Temperature: 450ºC

• The forward reaction is exothermic, so increasing the temperature shifts the position of equilibrium to the left in the direction of the reactants
• Therefore the higher the temperature, the lower the yield of sulfur trioxide
• The optimum temperature is a compromise between a higher rate of reaction at a higher temperature and a lower equilibrium yield at a higher temperature

Pressure: 2 atm

• An increase in pressure shifts the position of equilibrium to the right in the direction of a smaller number of gaseous molecules
• However the position of equilibrium lies far to the right (the equilibrium mixture contains about 96% sulfur trioxide)
• So the reaction is carried out at just above atmospheric pressure because:
  
  • High pressures can be dangerous and very expensive equipment is needed 
  • A higher pressure causes the sulfur dioxide to liquefy